Motion simulation system and method

ABSTRACT

The various embodiments described herein include methods, devices, and systems for simulating motion. In one aspect, a motion simulation system includes a weight bearing actuator and a positioning actuator assembly. The weight bearing actuator includes a pneumatic cylinder defining a cavity and a piston rod disposed at least partially within the cavity of the pneumatic cylinder. The first end of the piston rod and the cavity of the pneumatic cylinder define a volume of the pneumatic cylinder. The volume of the pneumatic cylinder is configured to be pressurized to support a weight of a payload. The positioning actuator assembly includes a positioning actuator with a stator and a rotor, and a connecting rod. The connecting rod is coupled to the rotor. The rotor is configured to rotate to translate the connecting rod and position the payload supported by the weight bearing actuator.

REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Pat. Application No. 63/308,421, filed Feb. 9, 2022, the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to motion simulation systems, including, but not limited to motion simulation systems including a platform assembly and configured for movement in multiple degrees of freedom.

BACKGROUND

Motion simulation systems have included platforms for supporting and initiating physical movement for participants in amusement attractions and simulation products, e.g., video gaming. Such systems have been designed to provide physical movement to participants in film or computer simulation/gaming activities. The Stewart platform (or hexapod) is a well-known form of simulator which moves a platform relative to a base.

In some applications, hexapods include six linear actuators arranged to move the platform in six degrees of freedom, particularly three linear and three rotational degrees of freedom, relative to the base, depending on which actuators are used in combination. The translational degrees of freedom are commonly known as surge (horizontal movement in the direction of travel), sway (horizontal movement perpendicular to the direction of travel), and heave (vertical motion). The rotational degrees of freedom are known as roll (rotation about an axis parallel to the direction of travel), pitch (rotation about a horizontal axis perpendicular to the direction of travel), and yaw (rotation about a vertical axis).

In certain applications, hexapods can have limited workspaces defined by the maximum and minimum excursion of the platform, which is further defined by the limit of travel of the actuators. For larger workspaces requiring further platform movement in any given degree of freedom, certain systems may utilize longer actuators, but such longer actuators may substantially increase costs attendant to the simulator and may also decrease the inherent stiffness of the simulator. Additionally, certain existing motion simulation systems may employ expensive, industrial grade components, further increasing simulator costs. In some applications, the primary cost driver of existing motion simulation systems is the motion effector subsystem, which includes actuating elements (servo motors), associated gear reduction elements, and associated feedback and control systems.

SUMMARY

Accordingly, there is a need for a motion simulation system capable of improved movement control and capabilities (e.g. greater frequency response), while also having lower manufacturing costs.

The present disclosure describes motion simulation systems to initiate physical movement for amusement and simulation purposes. In some embodiments, the motion simulation system includes one or more weight bearing actuators and one or more positioning actuator assemblies.

The motion simulation system can include a plurality of weight bearing actuators and a plurality of positioning actuator assemblies. In various embodiments, the motion simulation system can include twice as many positioning actuator assemblies as weight bearing actuators. In some embodiments, the motion simulation system can include three weight bearing actuators and six positioning actuator assemblies. In some embodiments, the end of a weight bearing actuator can be adjacent to ends of a first and second positioning actuator assemblies. The motion simulation system can allow for six degrees of freedom.

The motion simulation system can include a platform. The platform can be coupled to the weight bearing actuators and the positioning actuator assemblies.

In some embodiments, the weight bearing actuator can include a buffer tank. The buffer tank can provide or define a dead volume. The buffer tank can be in fluid communication with the pneumatic cylinder. The buffer tank can increase the dead volume of the weight bearing actuator. For example, the dead volume can be approximately 100% to 500% of the swept volume of the pneumatic cylinder. In some embodiments, the pneumatic cylinder can be filled by oscillating the piston rod.

In some embodiments, the positioning actuator assembly includes a crank pivotably coupled to the rotor and the connecting rod. The crank can be integrally formed with the rotor.

In some embodiments, the weight bearing actuator and the positioning actuator assembly are at least partially disposed within a linear actuator housing. The connecting rod of the positioning actuator assembly can be coupled to the piston rod of the weight bearing actuator. In some embodiments, an end of the connecting rod is pivotably coupled to the piston rod between the first end and a second end of the piston rod.

In some embodiments, the motion simulation system includes a controller to control the operation of the weight bearing actuator and the positioning actuator. In various embodiments, the controller can detect a current draw of the positioning actuators. In some embodiments, the controller is configured to pressurize the volume of the pneumatic cylinder to a pressure to minimize a current draw of the positioning actuator. In various embodiments, the controller is configured to control operation of the positioning actuator at a frequency of up to approximately 1000 Hz.

In various embodiments, the controller of the motion simulation system can compare a rotational position of the positioning actuators with a desired rotational position of the positioning actuators for closed loop control of the motion control system. In some embodiments, the controller can adjust a gain factor in response to comparing the rotational position of the positioning actuators with the desired rotational position of the positioning actuators.

In some embodiments, the motion simulation system includes an electrical storage device to receive energy generated by the positioning actuator and deploy the energy into the motion simulation system.

As discussed previously, certain conventional motion simulation systems can be costly and may have a relatively low frequency response and inherent stiffness. The present disclosure includes embodiments that allow for improved movement control, increased frequency response, and increased inherent stiffness, while providing for lower component and manufacturing costs. Embodiments of the present disclosure can utilize direct-drive actuator arrangements and eliminate gear reduction elements. Further, embodiments of the present disclosure can utilize rotary or linear encoders to provide additional control to non-servo motors. Additionally, embodiments of the present disclosure can allow for forced ventilation of actuators to increase cooling.

In one aspect, some embodiments include a motion simulation system including a weight bearing actuator including: a pneumatic cylinder defining a cavity; and a piston rod disposed at least partially within the cavity of the pneumatic cylinder, wherein a first end of the piston rod and the cavity of the pneumatic cylinder define a volume of the pneumatic cylinder, and the volume of the pneumatic cylinder is configured to be pressurized to support a weight of a payload; and a positioning actuator assembly including: a positioning actuator including: a stator; and a rotor configured to rotate relative to the stator; and a connecting rod coupled to the rotor, wherein the rotor is configured to rotate to translate the connecting rod and position the payload supported by the weight bearing actuator.

In another aspect, some embodiments include a motion simulation system including: a base; a platform movable relative to the base and configured to support a payload; a plurality of weight bearing actuators, wherein each weight bearing actuator includes: a pneumatic cylinder pivotably coupled to the base, wherein the pneumatic cylinder defines a cavity; and a piston rod defining a first end and a second end, wherein the first end is disposed at least partially within the cavity of the pneumatic cylinder to define a volume of the pneumatic cylinder, the second end is pivotably coupled to the platform, and the volume of pneumatic cylinder is configured to be pressurized to support the platform; and a plurality of positioning actuator assemblies, wherein each positioning actuator assembly includes: a positioning actuator coupled to the base, the positioning actuator including: a stator; and a rotor configured to rotate relative to the stator; and a connecting rod including a first end pivotably coupled to the rotor and a second end pivotably coupled to the platform, wherein the rotor is configured to rotate to translate the connecting rod and position the payload supported by the plurality of weight bearing actuators.

In another aspect, some embodiments include a method to operate a motion simulation system, including pressurizing a plurality of weight bearing actuators to support a platform relative to a base; and moving the platform by rotating a plurality of positioning actuators of a respective plurality of positioning actuator assemblies, wherein each positioning actuator assembly is pivotably coupled to the platform via a respective connecting rod of the plurality of positioning actuator assemblies.

In another aspect, some embodiments include a configured to perform any of the methods described herein. In another aspect, some embodiments include a non-transitory computer-readable storage medium storing one or more programs, the one or more programs comprising instructions which, when executed by a system, cause the system to perform any of the methods described herein.

Thus, systems and methods are provided for simulating motion with more effective movement control while reducing component and manufacturing costs, thereby increasing the performance and reducing the overall cost of such systems and devices.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the various described embodiments, reference should be made to the Description of Embodiments below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.

FIG. 1 is a perspective view of a motion simulation system with a payload in accordance with some embodiments.

FIG. 2 is a perspective view of a motion simulation system in accordance with some embodiments.

FIG. 3 is a perspective view of a weight bearing actuator of the motion simulation system of FIG. 2 in accordance with some embodiments.

FIG. 4 is a cross-sectional view of a weight bearing actuator of the motion simulation system of FIG. 2 in accordance with some embodiments.

FIG. 5 is a perspective view of a positioning actuator assembly of the motion simulation system of FIG. 2 in accordance with some embodiments.

FIG. 6 is a perspective view of a positioning actuator of the positioning actuator assembly of FIG. 5 in accordance with some embodiments.

FIG. 7 is a see-through perspective view of a positioning actuator of the positioning actuator assembly of FIG. 5 in accordance with some embodiments.

FIG. 8A is a perspective view of a motion simulation system in accordance with some embodiments.

FIG. 8B is a side elevation view of a positioning actuator assembly of the motion simulation system of FIG. 8A, in accordance with some embodiments.

FIG. 8C is a perspective view of a motion simulation system in accordance with some embodiments.

FIG. 8D is a side elevation view of a positioning actuator assembly of the motion simulation system of FIG. 8C, in accordance with some embodiments.

FIG. 8E is a perspective view of a positioning actuator assembly in accordance with some embodiments.

FIG. 9 is a perspective view of a motion simulation system with a payload in accordance with some embodiments.

FIG. 10 is a perspective view of a motion simulation system in accordance with some embodiments.

FIGS. 11A-11G are each perspective views of a motion simulation system in accordance with some embodiments.

FIG. 12 is a perspective view of a motion simulation system in accordance with some embodiments.

FIG. 13 is a perspective view of an integrated linear actuator unit of the motion simulation system of FIG. 12 in accordance with some embodiments.

FIG. 14 is an elevation view of an integrated linear actuator unit of FIG. 13 .

FIG. 15 is a perspective view of a weight bearing actuator of the integrated linear actuator unit of FIG. 13 in accordance with some embodiments.

FIG. 16 is a perspective view of a motion simulation system in accordance with some embodiments.

FIG. 17 is a perspective view of a haptic device in accordance with some embodiments.

FIG. 18 is an elevation view of the haptic device of FIG. 17 .

DETAILED DESCRIPTION

The present disclosure describes various embodiments of motion simulation systems. In some embodiments, a motion simulation system includes weight bearing actuators and positioning actuators, such that the weight bearing actuators support the weight of the payload, minimizing the weight the positioning actuators must support. In some applications, the use of weight bearing actuators can allow for the use of direct drive positioning actuators. Advantageously, by minimizing the weight the positioning actuators must support, embodiments of the motion simulation system can utilize smaller and cost-effective actuators that provide improved movement control and high frequency response (in some embodiments up to 1000 Hz) while providing a desired range of motion and degrees of freedom (e.g. six degrees of freedom).

FIG. 1 is a perspective view of a motion simulation system 100 with a payload 10 in accordance with some embodiments. FIG. 2 is a perspective view of a motion simulation system 100 in accordance with some embodiments. With reference to FIGS. 1 and 2 , the motion simulation system 100 supports and/or positions a payload 10 relative to a base 110 to provide motion information, signals, or other feedback to a user. In some embodiments, the payload 10 can include, but is not limited to, a user, a seat, and/or hardware. In some embodiments, the hardware can include, but is not limited to automotive simulation hardware (e.g. a steering wheel and pedals), aviation simulation hardware, or other suitable hardware. In some applications, the payload 10 can be in excess of 100 kilograms. While embodiments of the motion simulation system may carry or move more payload than certain conventional motion simulation systems, the payload capacity of an embodiment of the motion simulation system may vary with the sizing and configuration of the motion simulation system.

As illustrated, a platform 120 can support and position the payload 10 relative to the base 110. In the depicted example, the platform 120 includes one or more legs 122 shaped, bent, or otherwise configured to receive, cradle, or otherwise support the payload 10. Portions of the payload 10 can be affixed or secured to the legs 122 of the platform 120. The legs 122 or other features of the platform 120 can be adapted for any suitable payload 10. In some embodiments, the platform 120 can be any suitable shape or configuration. For example, the platform 120 can have a planar shape, such as a disk, to allow for a flat surface to support the payload 10. In some embodiments, the shape of the platform 120 may be symmetrical or asymmetrical and may otherwise vary.

In the depicted example, the base 110 can support weight of the platform 120 and the payload 10, as well as the other components of the motion simulation system 100. As illustrated, the base 110 can have a generally hexagonal shape. In some embodiments, the shape of the base 110 may be symmetrical or asymmetrical and may otherwise vary.

As described herein, one or more weight bearing actuators 130 can support the weight of the platform 120 and the payload 10 relative to the base 110. Further, one or more positioning actuator assemblies 140 can move or position the platform 120 and the payload 10 relative to the base 110.

FIG. 3 is a perspective view of a weight bearing actuator 130 of the motion simulation system 100 of FIG. 2 in accordance with some embodiments. FIG. 4 is a cross-sectional view of a weight bearing actuator 130 of the motion simulation system 100 of FIG. 2 in accordance with some embodiments. With reference to FIGS. 1-4 , each weight bearing actuator 130 can support the platform 120 and the payload 10 at a desired pose relative to the base 110. In the depicted example, the weight bearing actuators 130 support the platform 120 and the payload 10 without affecting a position of the platform 120 during normal operation.

In the depicted example, the weight bearing actuator 130 is coupled to the platform 120 and the base 110. As illustrated, one end 136 of the weight bearing actuator 130 can be coupled to the base 110 and an opposing end 136 of the weight bearing actuator 130 can be coupled to the platform 120. In some embodiments, an end 136 can be coupled to an end portion 124 of the legs 122 or any other suitable portion of the platform 120. In some embodiments, the placement of the joints, connections, or ends 136 of the weight bearing actuators 130 relative to the platform 120 and/or base 110 may be co-planar, non-coplanar, symmetric, non-symmetric, or may otherwise vary. In some embodiments, the ends 136 can be pivotably coupled to the base 110 and the platform 120. The ends 136 may include ball joints.

Prior to normal operation of the motion simulator system 100, the weight bearing actuators 130 can be extended to a desired length to serve as a leg or otherwise support the platform 120 and the payload 10 at a desired pose. In the depicted example, the weight bearing actuator 130 is a pneumatic actuator that utilize air pressure to extend and support the platform 120 and the payload 10 at the desired pose. In some embodiments, the pneumatic actuator includes a piston rod 134 that is movable relative to a pneumatic cylinder 132.

As illustrated, a first end of a piston rod 134 is at least partially disposed within a cavity of a pneumatic cylinder 132 to define a cylinder volume 133. During operation, the cylinder volume 133 can be pressurized to advance the piston rod 134 and support the platform 120. As described herein, the pressure of the cylinder volume 133 can be adjusted to adjust the position of the piston rod 134 relative to the pneumatic cylinder 132 and support various payload weights, platform heights and/or poses. In some embodiments, the second end 136 of the piston rod 134 is coupled to the platform 120. In some embodiments, the second end 136 of the piston rod 134 may have a travel of approximately 100 mm to 200 mm. Further, in some embodiments, the piston rod 134 may have a diameter of approximately 30 mm to 50 mm and may be capable of exerting a force of approximately 500 to 1500 N.

In some embodiments, the pneumatic cylinder 132 can be pressurized by a pneumatic control circuit. The pneumatic control circuit can include a compressor to pressurize the cylinder volume 133 to a desired pressure via port 139. The pneumatic control circuit can introduce, relieve, or otherwise control pressure within the cylinder volume 133 via port 139. In some embodiments, the motion simulation system 100 may be able to self-pressurize the pneumatic actuator by utilizing the piston rod 134 as a pumping element. During a self-pressurization or compressor-less procedure, the positioning actuator assemblies 140 may move the platform through an appropriate series of poses (e.g. oscillating the platform 120 along the vertical or heave axis) and selectively actuate control elements of the pneumatic control system to allow the oscillation of the piston rod 134 coupled to the platform 120 to pressurize the cylinder volume 133 to a desired pressure. In some embodiments, the pneumatic cylinder 132 can include a one-way valve to allow for air to enter the cylinder volume 133 and be compressed by the piston rod 134 without escaping the cylinder volume 133 during the self-pressurization procedure.

In some applications, the state or extension of the weight bearing actuators 130 to support the platform 120 and the payload 10 at a desired pose relative to the base 110 can be determined by a calibration process. For example, a calibration process can determine and provide a desired pressure within the cylinder volume 133 of each of the weight bearing actuators 130 to support the platform 120 and the payload 10 at a desired pose relative to the base 110. In some embodiments, the weight bearing actuators 130 can be calibrated to support the platform 120 and payload 10 at a pose that allows the motion simulation system 100 to move the platform 120 through a desired range of motion, which may be located at a center of the motion simulation system’s 100 motion envelope. In some embodiments, the weight bearing actuators 130 can be calibrated to support the platform 120 at a pose that is offset from the center of the motion simulation system’s 100 motion envelope. For example, the weight bearing actuators 130 can be calibrated to support the platform 120 at a position that is higher or lower than the center of the motion simulation system’s 100 motion envelope.

In some embodiments, a calibration process may begin by using the positioning actuator assemblies 140 to place the platform 120 in static equilibrium in a preselected pose, which may referred to as a zero position pose. As described herein, a controller can determine the weight of the platform 120 and the supported payload 10 by detecting the load experienced by the positioning actuator assemblies 140. In some embodiments, the load on the positioning actuator assemblies 140 can be determined by current feedback signals analyzed by a controller.

After determining a weight of the platform 120 and any supported payload 10, the cylinder volumes 133 of each respective weight bearing actuator 130 can be pressurized to minimize the load experienced by the positioning actuator assemblies 140. In some embodiments, minimization of current signals from the positioning actuator assemblies 140 can be used as feedback for closed loop control of pressurization of the weight bearing actuators 130. As described herein, the weight bearing actuators 130 can be pressurized using the pneumatic circuit (i.e. compressor) or via self-pressurization via oscillation of the platform 120.

In some embodiments, after the calibration process, the pressure of the cylinder volume 133 of each respective weight bearing actuator 130 is established as the equilibrium pressure to support the platform 120 and payload 10 at a desired pose. Similarly, the stroke of the piston rod 134 relative to the pneumatic cylinder 132 of each respective weight bearing actuator 130 is established as the equilibrium distance or stroke to support the platform 120 and payload 10 at the desired pose. The equilibrium pressure and distance can vary between each weight bearing actuator 130. After calibration, each weight bearing actuator 130 can be pneumatically isolated from the pneumatic circuit. Advantageously, the calibrated weight bearing actuators allow the motion simulation system 100 to maintain the zero position pose with a minimal amount of torque (and power) from the positioning actuator assemblies 140, since the weight of the platform 120 and the payload 10 is supported or counterbalanced by the weight bearing actuators 130.

In some applications, certain pneumatic actuators may exert a different force based on the position of the piston rod within the variable or swept volume of the actuator. For example, without taking into consideration the effects of temperature, certain pneumatic actuators may exert less actuation force as the piston rod is extended, since the cylinder volume is expanded and the pressure is reduced, and may exert more actuation force as the piston rod is contracted, since the cylinder volume is compressed and the pressure is increased. In certain pneumatic actuators, the force exerted by the actuator may be inversely proportional to the piston position.

In some embodiments, the weight bearing actuator 130 can provide a relatively large non-variable or dead volume in comparison to the variable swept volume of the pneumatic cylinder 132 and piston rod 134 to minimize variations in pressure and therefore actuation force as the piston rod 134 moves through its stroke. In the depicted example, the weight bearing actuator 130 includes a buffer tank 138 in fluid communication with the pneumatic cylinder 132 to provide additional dead volume to the pneumatic cylinder 132. As illustrated, the dead volume of the buffer tank 138 can be in fluid communication with the cylinder volume 133 via the port 139. Advantageously, since the dead volume of the buffer tank 138 is significantly larger than the variable volume of the cylinder volume 133, overall variations in pressure in the weight bearing actuator 130 (i.e. volume of the buffer tank 138 and the cylinder volume 133 combined) as the cylinder volume 133 changes are minimized, similarly minimizing changes in force provided by the weight bearing actuator 130. In some embodiments, the dead volume of the buffer tank 138 is 100% to 500% the variable swept volume of the cylinder volume 133.

In some embodiments, the weight bearing actuators 130 can provide mechanical damping between moving and fixed parts of the motion simulation system 100. In some embodiments, the magnitude of damping effect can be adjusted by controlling the rate of air flow between the buffer tank 138 and an extension chamber of the pneumatic cylinder 132 and/or between the contraction chamber of the pneumatic cylinder 132 and the environment. In some embodiments, the rate of air flow can be adjusted during operation to dynamically adjust the magnitude of damping effect provided by the weight bearing actuators 130. Further, the weight bearing actuators 130 may recover and/or recuperate energy from the platform 120 and payload 10 by acting as a spring.

In some embodiments, the weight bearing actuator 130 can be an active or passive device and may utilize other types of actuators, including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and/or rotary springs. As described herein, the force exerted by the weight bearing actuator 130 can be adjustable. For example, certain weight bearing actuators may include an adjustable or programmable spring. In some embodiments, a programmable spring may include a series elastic actuator (SEA) including an actuator coupled to a load via an elastic element (e.g., one or more springs) and a sensor to measure a degree of force being transferred through the elastic element. A control loop may be programmed to produce a system that can apply a specified force to the load and make the actuator behave like a spring with the desired stiffness.

In some embodiments, the force exerted by a weight bearing actuator 130 may be pre-set or otherwise not readily adjustable. For example, certain weight bearing actuators 130 may be configured for a fixed payload and may be initially adjusted or fabricated to provide an appropriate weight bearing force. In certain embodiments, certain weight bearing actuators 130 can be configured for a fixed payload and may initially adjusted or fabricating utilizing a similar calibration procedure as described herein.

As described herein, the weight bearing actuators 130 can be arranged or otherwise disposed relative to the base 110 and the platform 120 in any suitable arrangement. For example, a motion simulation system 100 can include twice as many positioning actuator assemblies 140 as weight bearing actuators 130. As illustrated, the motion simulation system 100 can include three weight bearing actuators 130. The weight bearing actuators 130 can be equidistantly disposed.

FIG. 5 is a perspective view of a positioning actuator assembly 140 of the motion simulation system 100 of FIG. 2 in accordance with some embodiments. With reference to FIG. 5 , each positioning actuator assembly 140 can move or position the platform 120 and the payload 10 to a desired pose relative to the base 110. In the depicted example, the positioning actuator assemblies 140 can collectively or cooperatively position the platform 120 in any six-dimensional pose relating to surge, sway, heave, yaw, pitch, and roll within the motion space envelope of the motion simulation system 100.

In the depicted example, the positioning actuator assembly 140 coupled to the platform 120 and the base 110. As illustrated, a positioning actuator 150 can be coupled to the base 110 and an end 148 of a connecting rod 146 can be coupled to the platform 120. In some embodiments, an end 148 of the connecting rod 146 can be coupled to an end portion 124 of the legs 122 or any other suitable portion of the platform 120. In some embodiments, the placement of the end 148 of a respective positioning actuator assembly 140 relative to the platform 120 may be co-planar, non-coplanar, symmetric, non-symmetric, or may otherwise vary. In some embodiments, the ends 148 of the connecting rod 146 can be pivotably coupled to the platform 120 and the positioning actuator 150. The ends 148 may include ball joints. In some embodiments, the placement of the positioning actuator 150 of a respective positioning actuator assembly 140 relative to the base 110 may be co-planar, non-coplanar, symmetric, non-symmetric, or may otherwise vary.

During operation of the motion simulation system 100, the positioning actuator assemblies 140 can extend, retract, translate, or otherwise move a respective connecting rod 146 to position the platform 120 and the payload 10 in a desired pose. In the depicted example, the positioning actuator assembly 140 includes a positioning actuator 150 to manipulate a connecting rod 146, which in turn (in conjunction with the other positioning actuator assemblies 140) positions the platform 120 in a desired pose.

In the depicted example, the positioning actuator 150 rotates a rotor 142 to adjust the position of the connecting rod 146, and in particular, the connecting rod end 148 pivotably coupled to the platform 120. As illustrated, a linkage, such as a crank 144 is coupled to the rotor 142 can rotate with the rotor 142 can move or translate an opposite connecting rod end 148 pivotably coupled to the crank 144. Rotation of the crank 144 can move or translate the connecting rod 146, and in turn the connecting rod end 148 coupled to the platform 120. In some embodiments, the length or geometry of the crank 144 can be altered to adjust the relationship between the rotation of the rotor 142 and the movement of the connecting rod 146. Further, in some embodiments, the positioning actuator can include a linear actuator.

Advantageously, the direct attachment or connection between the connecting rod 146, the crank 144, and the rotor 142 of the positioning actuator 150 allows for a direct-drive mechanism or arrangement adjust the position of the platform 120. Further, the absence of intervening or intermediate machine or power transmission elements allows for direct and immediate transfer of the weight and inertia of the platform 120 and payload 10 to the positioning actuator 150 and allows for increased system stiffness and response, permitting the motion simulation system 100 to reject or overcome static external disturbances (e.g. when an axis is holding a position or speed) and dynamic external disturbances (e.g. when an axis is following a position or speed trajectory).

In certain conventional applications, the use of direct drive mechanisms may require conventional positioning actuators to directly bear the weight of the platform and payload. Therefore, in certain applications, even during static equilibrium, conventional actuators are required to exert constant torque to counterbalance the weight of the platform and payload, increasing energy consumption and demands on the actuators. Advantageously, the use of weight bearing actuators 130 support the load of the platform 120 and the payload 10 enables the use of direct drive positioning actuator assemblies 140 that are not required to directly or constantly bear the weight of the platform 120 and payload 10. The use of weight bearing actuators 130 allows for smaller, lighter, less expensive actuators and other components within the positioning actuator assembly 140 and permits reduced energy consumption, while allowing for a desired performance.

FIG. 6 is a perspective view of a positioning actuator 150 of the positioning actuator assembly 140 of FIG. 5 in accordance with some embodiments. FIG. 7 is a see-through perspective view of a positioning actuator 150 of the positioning actuator assembly 140 of FIG. 5 in accordance with some embodiments. With reference to FIGS. 5-7 , the positioning actuator 150 rotates the rotor 142 relative to a stator disposed within the housing of the positioning actuator 150. In some embodiments, the positioning actuator 150 includes a rotary encoder 152 to determine the rotational position of the rotor 142 relative to the stator or other stationary portions of the positioning actuator 150. Signals from rotary encoder 152 can be used as feedback for closed loop control of the positioning actuator assembly 140 and the motion control system 100, generally. In some embodiments, the positioning actuator 150 can include a fan 156 to actively cool components of the positioning actuator 150. The fan 156 can draw in cool air or expel heat through a fan housing 154 formed in the positioning actuator 150.

As described herein, embodiments of a positioning actuator assembly can include a connecting rod with ball joint ends that allow for the pivot or rotation of the connecting rod relative to the positioning actuator and the platform, while permitting the positioning actuator to control a position of the platform. In some applications, certain ball joints may have a limited swivel angle, potentially limiting the motion of the connecting rod, and in turn the positioning actuator assembly which may result in limiting the motion envelope of the motion simulation system. For example, certain ball joints may have a swivel angle range of approximately ±10 degrees, ±15 degrees, or ±20 degrees.

Further, in certain applications, certain positioning actuator assemblies are positioned such that the motion simulation system cannot utilize the full swivel angle range of the ball joints, potentially limiting the motion envelope of the motion simulation system for a given ball joint swivel angle range. For example, certain positioning actuator assemblies may be positioned such that when the motion simulation system is in a preselected, resting, or zero position pose, the ball joint ends of the respective connecting rods disposed or positioned away from the midpoint of their respective swivel angle range. As a result, in certain applications, the ball joint ends may swivel more in one direction and swivel less in another direction, relative to the zero position pose. In some applications, the reduced swivel travel relative to the zero position pose may impose a limit for the overall motion envelope of the motion simulation system.

FIG. 8A is a perspective view of a motion simulation system 200 a in accordance with some embodiments. FIG. 8B is a side elevation view of a positioning actuator assembly 240 a of the motion simulation system 200 a of FIG. 8A, in accordance with some embodiments. In some embodiments, one or more of the positioning actuator assemblies 240 a can be configured to increase the range of motion or motion envelope of the motion simulation system 200 a compared to certain conventional motion simulation systems. In some embodiments, the motion simulation system 100 can utilize other types, constructions, or configurations of actuator assemblies or actuators as depicted by their implementation in other systems.

In some embodiments, one or more of the positioning actuator assemblies 240 a can be positioned or disposed to avoid limiting or to otherwise increase the usable range of motion of the joint ends 248 a, which in turn would increase the range of motion of the positioning actuator assemblies 240 a and the motion envelope of the motion simulation system 200 a. In the depicted example, positioning actuator assemblies 240 a can be positioned such that when the motion simulation system 200 a is in a preselected, resting, or zero position pose, the ball joint ends 248 a of the respective connecting rods 246 a can be disposed or positioned approximately at or near the midpoint of their respective swivel angle range. In some applications, the ball joint ends 248 a can be configured to be positioned approximately at or near the midpoint of their respective swivel angle range when the weight bearing actuators 230 a are disposed in an equilibrium configuration or position. By allowing the ball joint ends 248 a to be positioned approximately at or near the midpoint of their respective swivel angle range when the motion simulation system 200 a is in a zero position pose, the ball joint ends 248 a may swivel approximately an equal amount in various directions relative to the zero position pose. Advantageously, the approximately equal swivel travel relative to the zero position pose can maximize the overall motion envelope of the motion simulation system 200 a for a given ball joint end 248 a.

In some embodiments, the position of the ball joint ends 248 a in the swivel angle range for a given position or pose can be adjusted by changing the angle between the horizontal plane and a motor rotation axis of the positioning actuator 250 a, also referred to as a motor dihedral angle. In the depicted example, the motor dihedral angle of the positioning actuator 250 a can be adjusted such that the ball joint ends 248 a can be positioned approximately at or near the midpoint of their respective swivel angle range when the motion simulation system 200 a is in a zero position pose. In some applications, the motor dihedral angle of the positioning actuator 250 a can be adjusted such that the ball joint ends 248 a are positioned at another desired position of their respective swivel range at a desired pose. As illustrated, the motor dihedral angle of the positioning actuator 250 a can be non-zero and positive. In some embodiments, the motor dihedral angle of the positioning actuator 250 a can range between approximately 0.1 degrees to approximately 20 degrees.

In some embodiments, the position of the ball joint ends 248 a in the swivel angle range for a given position or pose can be adjusted by changing the angle between the platform 220 a base plane and a ball joint end 248 a axis, also referred to as a platform dihedral angle. In the depicted example, the platform dihedral angle of the platform 220 a can be adjusted such that the ball joint ends 248 a can be positioned approximately at or near the midpoint of their respective swivel angle range when the motion simulation system 200 a is in a zero position pose. In some applications, the platform dihedral angle of the platform 220 a can be adjusted such that the ball joint ends 248 a are positioned at another desired position of their respective swivel range at a desired pose. As illustrated, the platform dihedral angle of the platform 220 a can be non-zero and positive. In some embodiments, the platform dihedral angle of the platform 220 a can range between approximately 0.1 degrees to approximately 20 degrees. In some applications, the motor dihedral angle and the platform dihedral angle may be the same, similar, or complementary. In some applications, the motor dihedral angle and the platform dihedral angle may differ.

FIG. 8C is a perspective view of a motion simulation system 200 b in accordance with some embodiments. FIG. 8D is a side elevation view of a positioning actuator assembly 240 b of the motion simulation system 200 b of FIG. 8C, in accordance with some embodiments. In some embodiments, the motor dihedral angle of the positioning actuator 250 b can be non-zero and negative. In some embodiments, the motor dihedral angle of the positioning actuator 250 b can range between approximately 0.1 degrees to approximately 20 degrees.

In some embodiments, the platform dihedral angle of the platform 220 b can be non-zero and negative. In some embodiments, the platform dihedral angle of the platform 220 b can range between approximately 0.1 degrees to approximately 20 degrees.

In some applications, the motor dihedral angle and the platform dihedral angle may be the same, similar, or complementary. In some applications, the motor dihedral angle and the platform dihedral angle may differ. Further, in some embodiments, the motor dihedral angle and the platform dihedral angle of certain portions of the motion simulation system may be positive or negative, or otherwise non-zero. In some applications, the use of non-zero motor dihedral angles and platform dihedral angles can allow for a smaller profile of the base, as well as for the overall motion simulation system.

FIG. 8E is a perspective view of a positioning actuator assembly 240 c in accordance with some embodiments. With reference to FIG. 8E, the motion simulation system 100 may utilize a positioning actuator assembly 240 c (in place of or in conjunction with positioning actuator assembly 140) that includes a crank 244 c that is integrated with the rotor 242 c. As illustrated, the crank 244 c can extend axially from a surface of the rotor 242 c, allowing a connecting rod 246 c to directly attach or couple to the rotor 242 c. During operation, the crank 244 c can rotate with the rotor 242 c to move or translate the connecting rod, and in turn adjust the position of the platform 120.

As illustrated, the positioning actuator assembly 240 c may have a non-zero motor dihedral angle and/or platform dihedral angle to maximize the swivel range of the ball joint ends 248 c relative to a zero position pose. In some embodiments, the positioning actuator assembly 240 c can have a negative motor dihedral angle and/or platform dihedral angle.

As described herein, the positioning actuator assemblies 140 can be arranged or otherwise disposed relative to the base 110 and the platform 120 in any suitable arrangement. In the depicted example, the positioning actuator assemblies 140 can be arranged to allow for the motion simulation system 100 to move in six degrees of freedom. As illustrated, the motion simulation system 100 can include six positioning actuator assemblies 140. The six positioning actuator assemblies 140 can be equidistantly disposed. For example, the positioning actuator assemblies 140 can be spaced apart between 500 mm to 1200 mm. In some embodiments, the positioning actuator assemblies 140 can be disposed in a “rotary hexapod” arrangement.

In some applications, the placement of the positioning actuator assemblies 140 may vary relative to the weight bearing actuators 130. As discussed above, a motion simulation system 100 can include twice as many positioning actuator assemblies 140 as weight bearing actuators 130. In some embodiments, each weight bearing actuator 130 can be disposed between two positioning actuator assemblies 140, forming three “leg sets” disposed around the base 110 and coupled to the platform 120. Further, in some embodiments, an end 136 of the piston rod 134 of a weight bearing actuator 130 coupled to the platform 120 can be disposed between the connecting rod ends 148 of two positioning actuator assemblies 140.

During operation, the motion simulation system 100 can utilize the positioning actuator assemblies 140 to place the platform 120 and the payload 10 in a desired pose or a streamed succession of poses in response to position input. In the depicted example, a controller of the motion simulation system 100 can receive a position input as a streamed succession of pose vectors. The pose vectors can be received at a streaming frequency. In some embodiments, the controller of the motion simulation system 100 is capable of receive and/or processing pose vectors at a streaming frequency up to approximately 1000 Hz. Further, in some embodiments the positioning actuator assemblies 140 are capable of positioning the platform 120 in various poses at a streaming frequency up to approximately 1000 Hz. In some applications, positioning actuator assemblies 140 can be activated simultaneously by utilizing certain features, including, but not limited to, parallel architecture with a synchronizing signal.

During a pre-processing stage, each received pose vector can be transformed or scaled. Further, each received pose vector can be processed with respect to a kinematic state of the system (e.g. to limit the maximum acceleration and/or velocity of the motion simulation system 100). Further, each received pose vector can be validated against the physical mechanical limits of the motion simulation system 100. In some embodiments, the motion simulation system 100 can have a minimum travel limit of approximately -100 mm to -50 mm and a maximum travel limit of approximately 50 mm to 100 mm, and a span of approximately 100 mm to 200 mm in the surge, sway, and heave motion axes. In some embodiments, the motion simulation system 100 can have a minimum travel limit of approximately -15 degrees to -5 degrees and a maximum travel limit of approximately 5 degrees to 15 degrees, and a span of approximately 10 degrees to 20 degrees in the heading/yaw, attitude/pitch, and bank/roll axes.

In the depicted example, a valid pose vector is then translated into a position vector for each respective positioning actuator assembly 140, which is commanded to the respective positioning actuator assembly 140. In some embodiments, the controller of the motion simulation system 100 utilizes inverse kinematics to control the position of the platform 120. For example, the controller processes the pose vector to provide an effector position vector, which may be the desired rotation angle of a respective positioning actuator 150. Therefore, a pre-described succession of input pose vectors can result in highly controlled motion of the platform 120. In some embodiments, the motion control system 100 can control operation of at least six positioning actuator assemblies 140 to provide six degrees of freedom. In some embodiments, the motion control system 100 can be “overactuated” and include more positioning actuator assemblies 140 than desired degrees of freedom. In some applications, the motion simulation system 100 can utilize “forward” or joint space control (i.e. individual control of each positioning actuator assembly 140), “inverse” or model space control (i.e. control of the motion of the platform 120 as a system), or a hybrid system that may alternate between joint space control or model space control under various circumstances. In some applications, the motion simulation system 100 may utilize forward kinematics and/or inverse dynamic control to control the position of the platform 120.

In some embodiments, while a controller of the motion simulation system 100 may collectively or cooperatively provide each positioning actuator assembly 140 an effector position vector to provide a desired platform 120 pose, the motion control simulation system 100 may have independent closed loop control of each positioning actuator assembly 140. For example, in some embodiments, the motion simulation system 100 may use position information or other operational information of the positioning actuator 150 to provide closed-loop feedback, adjustment, or control of the input signal to the positioning actuator 150 to provide a desired position or pose.

As described herein, each positioning actuator 150 can include a rotary encoder 152 to provide position information to the motion simulation system 100. In some embodiments, the positioning actuator can include a linear actuator with a linear encoder to provide position information to the motion simulation system. The motion simulation system 100 can compare the position information from the rotary encoder 152 to the desired position provided by the effector position vector to adjust the signal or current provided to the positioning actuator 150 to control the positioning of the positioning actuator 150. Further, in some embodiments, the motion simulation system 100 can regulate current through the motor coils of the positioning actuator 150, recognizing that current is proportional to the torque output at the rotor 142. Current sensors can provide a feedback signal to allow for closed-loop control of the torque output and operation of the positioning actuator 150. In some embodiments, the feedback signals described herein can be processed by a multi-stage control loop of the motion simulation system 100 to generate an appropriate control system response.

Optionally, the response of the control loop for one or more of the positioning actuation assemblies 140 can be configured by selecting and adjusting one or more gain factors. In some embodiments, gain factors can be set independently and individually for each positioning actuator assembly 140 and dynamically modified during system operation. Therefore, the positioning actuation assemblies 140 and the motion simulation system 100 generally can be configured to react in various ways, depending on any suitable combination of available and selectable drivers. Advantageously, performance of the motion simulation system 100 can be optimized under diverse conditions, including but not limited to, kinematic operational requirements, payload 10 and payload mass distribution, and platform 120 position. In some embodiments, prior to normal operation, gain factors for control of the positioning actuation assemblies 140 can initially be set according to kinematic operational requirements, payload 10 and payload mass distribution, and platform 120 position.

Advantageously, in some applications, due to the direct-drive arrangement of the positioning actuator assemblies 140, the motion simulation system 100 can recover or recuperate energy for later use. In some embodiments, the positioning actuators 150 can recover kinetic and/or potential energy from the platform 120. During operation, motion of the platform 120 can energize or back-drive the positioning actuators 150, generating electrical energy.

The electrical energy generated by the positioning actuators 150 can be stored in the form of electrical potential energy. In some embodiments, the electrical energy can be stored in an energy storage device, such as an ultracapacitor, a supercapacitor, a capacitor, a battery, any other suitable energy storage device, or a combination thereof. In some embodiments, the energy storage device can store energy from multiple recovery events. The energy stored in the energy storage device can be deployed back into the motion simulation system 100 as needed. The energy storage device may be connected in parallel with the power supply of the motion simulation system 100. During operation, the energy storage device can rapidly deploy electrical energy in response to high peak current demands that may exceed the capabilities of certain power supplies. Advantageously, the capture, storage, and deployment of electrical energy can supplement the capabilities of the power supply of the motion simulation system 100, allowing for less demand on the power supply. Advantageously, by reducing power demands on the power supply, the power supply can be downsized without compromising the kinematic performance of the motion simulation system 100. In some applications that include a battery energy storage device, the motion simulation system may include components or control systems to maintain the health and integrity of the battery.

FIG. 9 is a perspective view of a motion simulation system 100 a with a payload 10 in accordance with some embodiments. FIG. 10 is a perspective view of a motion simulation system 100 a in accordance with some embodiments. With reference to FIGS. 9 and 10 , motion simulation system 100 a include certain features that are similar to the features of motion simulation system 100. Therefore certain features of motion simulation system 100 a that are similar to features of motion simulation system 100 are identified with similar reference numerals.

In the depicted example, the motion simulation system 100 a includes a curved platform 120 a to support the payload 10. In the depicted example, the platform 120 a includes one or more curved legs 122 a that are shaped to cradle or otherwise support the payload 10. In some embodiments, the curved legs 122 a can be vertical and/or horizontally curved. Optionally, the curved legs 122 a can define a compound curve in multiple planes. As illustrated, in some embodiments, the curved legs 122 a can be configured to support or cradle an automotive seat. Portions of the payload 10 can be affixed or secured to the legs 122 a of the platform 120 a. The legs 122 a or other features of the platform 120 a can be adapted for any suitable payload 10.

In some embodiments, an end of the weight bearing actuator 130 can be coupled to a middle portion 124 a of the legs 122 a or any other suitable portion of the platform 120 a. Further, in some embodiments, an end of the positioning actuator assembly 140 can be coupled to a middle portion 124 a of the legs 122 a or any other suitable portion of the platform 220.

FIGS. 11A-11G are each perspective views of a motion simulation system 300 a through 300 g in accordance with some embodiments. FIGS. 11A-11G illustrate various embodiments of motion simulation systems in accordance with the present disclosure that utilize positioning actuator assemblies 340 and weight bearing actuators 330. In some applications, the positioning actuator assemblies 340 and weight bearing actuators 330 depicted herein may be substituted with any other acceptable positioning actuator assembly and weight bearing actuator, including components described herein. Additionally, a mixture of different types of positioning actuator assemblies 340 and/or weight bearing actuators 330 is also possible. In some applications, a six degree-of-freedom motion simulation system may employ a minimum of six positioning actuator assemblies 340. However, in some embodiments, a six degree-of-freedom motion simulation system may be “overactuated” and include more than six positioning actuator assemblies 340. Similarly, the number of weight bearing actuators 330 can also vary. In some applications, the arrangement and configuration of the positioning actuator assemblies 340 and the weight bearing actuators 330 described herein can be implemented with any other suitable motion simulation system described herein.

In some embodiments, arrangement and positioning of the positioning actuator assemblies 340 and/or weight bearing actuators 330 can be symmetrical or non-symmetrical. The arrangement and positioning of the weight bearing actuators 330 with respect to the positioning actuator assemblies 340 can vary as well. Further, the shape of the base 310 and the shape of the platform 320 can vary, with such shapes being symmetrical or non-symmetrical. The arrangement and positioning of the joints with respect to the base 310 and/or the platform 320 can vary, such as by being co-planar or not co-planar, symmetrical or non-symmetrical, etc.

As illustrated in FIGS. 11A-11G, in some embodiments, the motion simulation system can utilize a circular platform 320 and a circular base 310. With reference to FIG. 11A, an embodiment of the motion simulation system 300 a includes six positioning actuator assemblies 340 and three weight bearing actuators 330, with each weight bearing actuator 330 being disposed between two adjacent positioning actuator assemblies 340.

In FIG. 11B, an embodiment of the motion simulation system 300 b includes nine positioning actuator assemblies 340 and three weight bearing actuators 330, with the nine positioning actuator assemblies 340 being arranged in groupings of three positioning actuator assemblies 340 and each weight bearing actuator 330 disposed between the separate groupings.

In FIG. 11C, an embodiment of the motion simulation system 300 c includes six positioning actuator assemblies 340 and three weight bearing actuators 330, with the six positioning actuator assemblies 340 being arranged in groupings of two positioning actuator assemblies 340 and each weight bearing actuator 330 disposed between the separate groupings.

In FIG. 11D, an embodiment of the motion simulation system 300 d includes six positioning actuator assemblies 340 and three weight bearing actuators 330, with the six positioning actuator assemblies 340 being arranged in groupings of two positioning actuator assemblies 340 and each weight bearing actuator 330 disposed in a more central position on the base 310, thereby supporting a more central location of the platform 320.

In FIG. 11E, an embodiment of the motion simulation system 300 e includes six positioning actuator assemblies 340 and six weight bearing actuators 330, with the six positioning actuator assemblies 340 being arranged in groupings of two positioning actuator assemblies 340, with a weight bearing actuator 330 disposed between each of the separate groupings and the three other weight bearing actuators 330 disposed in a more central position on the base 310, thereby supporting a more central location of the platform 320.

In FIG. 11F, an embodiment of the motion simulation system 300 f includes six positioning actuator assemblies 340 and nine weight bearing actuators 330, with the six positioning actuator assemblies 340 being arranged in groupings of two positioning actuator assemblies 340, with a weight bearing actuator 330 disposed between the two positioning actuator assemblies 340 of each grouping and between each of the separate groupings, with the three other weight bearing actuators 330 disposed in a more central position on the base 310, thereby supporting a more central location of the platform 320.

In FIG. 11G, an embodiment of the motion simulation system 300 g includes seven positioning actuator assemblies 340 and three weight bearing actuators 330, with each weight bearing actuator 330 being disposed between two adjacent positioning actuator assemblies 340 and the seventh positioning actuator assembly 340 being disposed in a more central position on the base 310, thereby supporting a more central location of the platform 320.

FIG. 12 is a perspective view of a motion simulation system 400 in accordance with some embodiments. FIG. 13 is a perspective view of an integrated linear actuator unit 460 of the motion simulation system 400 of FIG. 12 in accordance with some embodiments. FIG. 14 is an elevation view of an integrated linear actuator unit 460 of FIG. 13 . FIG. 15 is a perspective view of a weight bearing actuator 430 of the integrated linear actuator unit 460 of FIG. 13 in accordance with some embodiments. With reference to FIGS. 12-15 , the motion simulation system 400 utilizes integrated linear actuator units 460 to support and position a payload relative to a base 410 to provide motion information, signals, or other feedback to a user.

As described herein, a platform 420 can support and position the payload relative to the base 410. In some embodiments, the platform 420 can include one or more legs 422 formed into a space frame configured to receive, cradle, or otherwise support the payload. Portions of the payload can be affixed or secured to the legs 422 of the platform 420. The legs 422 or other features of the platform 420 can be adapted for any suitable payload. In some embodiments, the platform 420 can be any suitable shape or configuration. In some embodiments, the shape of the platform 420 may be symmetrical or asymmetrical and may otherwise vary. FIG. 16 is a perspective view of a motion simulation system 400 a in accordance with some embodiments. As illustrated in FIG. 16 , with respect to motion simulation system 400 a, in some embodiments, the platform 420 a may have a flat or planar shape. In some embodiments, the platform 420 a may have a generally circular or disk-like shape.

In the depicted example, the base 410 can support weight of the platform 420 and the payload, as well as the other components of the motion simulation system 400. As illustrated, the base 410 can have a generally circular or disk-like shape. In some embodiments, the shape of the base 410 may be symmetrical or asymmetrical and may otherwise vary.

As described herein, the platform 420 and any payload can be supported and positioned to a desired pose relative to the base 410 by one or more integrated linear actuator units 460. In the depicted example, each integrated linear actuator unit 460 includes a weight bearing actuator 430 to support the weight of the platform 420 and any payload and a positioning actuator assembly 440 to position the platform 420 and any payload, both disposed at least partially in a common housing 462 of the integrated linear actuator unit 460.

In the depicted example, the integrated linear actuator units 460 is coupled to the platform 420 and the base 410. As illustrated, one end 436 of the weight bearing actuator 430 of the integrated linear actuator unit 460 can be coupled to the base 410 and an opposing end 436 of the weight bearing actuator 430 can be coupled to the platform 420. In some embodiments, an end 436 can be coupled to an end portion 424 of the legs 422 or any other suitable portion of the platform 420. In some embodiments, the placement of the joints, connections, or ends of the integrated linear actuator units 460 relative to the platform 420 and/or base 410 may be co-planar, non-coplanar, symmetric, non-symmetric, or may otherwise vary. In some embodiments, the ends 436 can be pivotably coupled to the base 410 and the platform 420. The ends 436 may include ball joints.

Prior to normal operation of the motion simulator system 400, the integrated linear actuator units 460 can be extended to a desired length to serve as a leg or otherwise support the platform 420 and the payload at a desired pose. As illustrated, each integrated linear actuator unit 460 includes a weight bearing actuator 430 to support the platform 420 and any payload at a desired relative pose relative to the base 410.

In the depicted example, the weight bearing actuator 430 supports the platform 420 and the payload without affecting a position of the platform 420 during normal operation. The weight bearing actuator 430 is coupled to the housing 462 of the integrated linear actuator unit 460. As illustrated, a piston rod 434 of the weight bearing actuator 430 extends through the housing 462. Further, an end 436 of the weight bearing actuator 430 extends through an opposite side of the housing 462.

In the depicted example, the weight bearing actuator 430 is a pneumatic actuator that utilize air pressure to extend and support the platform 420 and the payload at the desired pose. In some embodiments, the weight bearing actuator 430 may include features and/or may operate in a manner that is similar to features and/or the manner of operation of the weight bearing actuator 130. Unless otherwise noted, similar reference numerals may be used to features of the weight bearing actuator 430 that are similar to the features of weight bearing actuator 130. In some embodiments, the weight bearing actuator 430 can utilize other types of actuators, including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and/or rotary springs.

In the depicted example, the weight bearing actuator 430 includes one or more buffer tanks 438 in fluid communication with the pneumatic cylinder 432 to provide additional dead volume to the pneumatic cylinder 432. In some embodiments, the one or more buffer tanks 438 can be coupled to a body of the pneumatic cylinder 432. As can be appreciated, the use of multiple buffer tanks 438 can allow for a desired dead volume while allowing for flexibility or configurability of the envelope of the weight bearing actuator 430. In some embodiments, the use of multiple buffer tanks 438 may allow for a relatively compact design to allow the pneumatic cylinder 432 and the buffer tanks 438 to be disposed within the housing 462 of the integrated linear actuator unit 460 while allowing for a desired dead volume.

During operation of the motion simulation system 400, the integrated linear actuator units 460 can be extended to a desired length to position the platform 420 and the payload in a desired pose. As illustrated, each integrated linear actuator unit 460 includes a positioning actuator assembly 440 to move or position the platform 420 and the payload to a desired pose relative to the base 410.

In the depicted example, the positioning actuator assembly 440 can impart a force or otherwise act upon the weight bearing actuator 430 of the same integrated linear actuator unit 460 to position (in conjunction or cooperatively with the other integrated linear actuator units 460) the platform 420 in any six-dimensional pose relating to surge, sway, heave, yaw, pitch, and roll within the motion space envelope of the motion simulation system 400. As illustrated, the positioning actuator assembly 440 is coupled to the weight bearing actuator 430 and the housing 462 of the integrated linear actuator unit 460. In some embodiments, an end 448 of the connecting rod 446 is pivotably coupled to the piston rod 434 of the weight bearing actuator 430 at a junction 464. As illustrated, the junction 464 between the connecting rod 446 and the piston rod 434 may be disposed between the pneumatic cylinder 432 and an end 436 of the piston rod 434. In some embodiments, the junction 464 can be disposed within the housing 462 of the integrated linear actuator unit 460. Further, the body of the positioning actuator can be coupled to the housing 462 of the integrated linear actuator unit 460.

In the depicted example, the positioning actuator assembly 440 includes a positioning actuator to manipulate the connecting rod 446, which in turn positions the piston rod 434 of the weight bearing actuator 430, and ultimately the platform 420 in a desired pose. In some embodiments, the positioning actuator assembly 440 may include features and/or may operate in a manner that is similar to features and/or the manner of operation of the positioning actuator assembly 140. Unless otherwise noted, similar reference numerals may be used to features of the positioning actuator assembly 440 that are similar to the features of positioning actuator assembly 140.

As described herein, the integrated linear actuator units 460 can be arranged or otherwise disposed relative to the base 410 and the platform 420 in any suitable arrangement. In the depicted example, the integrated linear actuator units 460 can be arranged to allow for the motion simulation system 400 to move in six degrees of freedom. As illustrated, the motion simulation system 400 can include six integrated linear actuator units 460. The six integrated linear actuator units 460 can be equidistantly disposed. In some embodiments, the integrated linear actuator units 460 can be disposed in a “linear hexapod” arrangement.

During operation, the motion simulation system 400 can utilize the integrated linear actuator units 460 to place the platform 420 and the payload in a desired pose or a streamed succession of poses in response to position input. In the depicted example, a controller of the motion simulation system 400 can receive a position input as a streamed succession of pose vectors. In some applications, the implementation of integrated linear actuator units 460 may simplify the mathematical complexity of the kinematic equations to convert the position input to a resulting motion of the motion simulation system 400.

Further, the present disclosure describes various embodiments of human machine interfaces (HMI). In some embodiments, a human machine interface can utilize direct drive actuators to accept motion input from an operator and to position an input portion of the interface to provide haptic feedback. The human machine interface or haptic device may be able to receive input with 6 degrees of freedom and provide haptic feedback with 6 degrees of freedom. In some applications, the human machine interface can include features, structures, and/or configurations of the motion simulation systems described herein. In some embodiments, such as certain low mass applications, the human machine interface may include or may not include weight bearing actuators.

FIG. 17 is a perspective view of a haptic device 500 in accordance with some embodiments. FIG. 18 is an elevation view of the haptic device 500 of FIG. 17 . With reference to FIGS. 17 and 18 , the haptic device 500 receives motion input from an operator through an input portion 502 and provides motion or haptic information, signals, or other feedback to a user via the same input portion 502. In some embodiments, the input portion 502 can be a knob, joystick, mouse, or any other suitable input device or structure.

As illustrated, a platform 520 can support, position, and move with the input portion 502 relative to the base 510. In the depicted example, the platform 520 can be shaped or configured to receive or otherwise support the input portion 502. Portions of the input portion 502 can be affixed or secured to the platform 520. In some embodiments, the platform 520 can have a planar shape, such as a disk, to allow for a flat surface to support the input portion 502. In some embodiments, the shape of the platform 520 may be symmetrical or asymmetrical and may otherwise vary.

In the depicted example, the base 510 can support weight of the platform 520 and the input portion 502, as well as the other components of the haptic device 500. As illustrated, the base 510 can have a generally triangular shape. In some embodiments, the shape of the base 510 may be symmetrical or asymmetrical and may otherwise vary.

In some applications, one or more weight bearing actuators 530 can support the weight of the platform 520, the input portion 502, and the operator’s applied weight relative to the base 510. In some embodiments, the weight bearing actuators 530 may include features, may operate, or otherwise may be implemented in a manner that is similar to features and/or the manner of operation of the weight bearing actuators described herein, including, but not limited to weight bearing actuator 130 and/or weight bearing actuator 430.

Prior to normal operation of the haptic device 500 the weight bearing actuators 530 can be extended to a desired length to serve as a leg or otherwise support the platform 520 and the input portion 502 at a desired pose. In some embodiments, the weight bearing actuator 530 for a haptic device 500 can utilize other types of actuators, including, but not limited to, gas struts, gas springs, elastic ropes, linear springs, coil springs, and/or rotary springs.

As described herein, the weight bearing actuators 530 can be arranged or otherwise disposed relative to the base 510 and the platform 520 in any suitable arrangement. For example, a haptic device 500 can include twice as many positioning actuator assemblies 540 as weight bearing actuators 530. As illustrated, the haptic device 500 can include three weight bearing actuators 530. The weight bearing actuators 530 can be equidistantly disposed. In some embodiments, such as certain low mass applications, the haptic device 500 may utilize the one or more positioning actuator assemblies 540 to support the weight of the platform 520, the input portion 502, and the operator’s applied weight relative to the base 510 without the use of weight bearing actuators.

In the depicted example, the haptic device 500 includes one or more positioning actuator assemblies 540 can receive motion input from the operator and position the platform 520 and the input portion 502 relative to the base 510. In the depicted example, the positioning actuator assembly 540 can receive motion input from the operator and position the platform 520 with respect to any six-dimensional pose relating to surge, sway, heave, yaw, pitch, and roll within the motion space envelope of the haptic device 500. In some embodiments, the positioning actuator assembly 540 may include features, may operate, or otherwise may be implemented in a manner that is similar to features and/or the manner of operation of the positioning actuator assemblies described herein, including, but not limited to positioning actuator assembly 140, positioning actuator assembly 240 and/or positioning actuator assembly 440.

As described herein, the positioning actuator assemblies 540 can be arranged or otherwise disposed relative to the base 510 and the platform 520 in any suitable arrangement. In the depicted example, the positioning actuator assemblies 540 can be arranged to allow for the haptic device 500 to receive position input and/or move in six degrees of freedom. As illustrated, the haptic device 500 can include six positioning actuator assemblies 540. The six positioning actuator assemblies 540 can be equidistantly disposed. As illustrated, the six positioning actuator assemblies 540 can be disposed in three “leg sets” disposed around the base 510 and coupled to the platform 520. In some embodiments, the positioning actuator assemblies 540 can be disposed in a “rotary hexapod” arrangement.

Advantageously, the direct attachment or connection between the components of the positioning actuator assembly 540 allows for a direct-drive mechanism or arrangement. In addition to the performance advantages described herein, the direct drive arrangement of the positioning actuator assemblies 540 allows for motion or other inputs by the operator through the input portion 502 and/or the platform 520 to provide the operator’s position input to another device, such as a computer. During operation, the motion of the input portion 502 and/or the platform 520 can energize or back-drive the positioning actuator assemblies 540 to generate signals corresponding to the position input of the operator.

In the depicted example, a controller of the haptic device 500 can receive a position input from the operator via a signal received from the positioning actuator assemblies 540. During operation, the controller of the haptic device 500 can convert or translate the signals of the positioning actuator assemblies 540 into a signal that can be utilized by a connected device (e.g. a computer) as a position input signal. In some embodiments, the controller of the haptic device 500 may utilize appropriate methods (e.g. forward kinematics) provide a desired position input signal to the connected device.

Further, as described herein with respect to other embodiments, the haptic device 500 can utilize the positioning actuator assemblies 540 to place the platform 520 and the input portion 502 in a desired pose or a streamed succession of poses in response to position input to provide haptic feedback to the operator. In the depicted example, a controller of the haptic device 500 can receive a haptic or position input as a streamed succession of pose vectors. In some embodiments, the controller of the haptic device 500 may include features, may operate, or otherwise may be implemented in a manner that is similar to features and/or the manner of operation of the controllers of the motion simulation systems described herein, including, but not limited to the controller of the motion simulation system 100.

It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first valve could be termed a second valve, and, similarly, a second valve could be termed a first valve, without departing from the scope of the various described embodiments. The first valve and the second valve are both valves, but they are not the same valve unless explicitly stated.

The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting” or “in accordance with a determination that,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event]” or “in accordance with a determination that [a stated condition or event] is detected,” depending on the context.

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the scope of the claims to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen in order to best explain the principles underlying the claims and their practical applications, to thereby enable others skilled in the art to best use the embodiments with various modifications as are suited to the particular uses contemplated. 

What is claimed is:
 1. A motion simulation system, comprising: a weight bearing actuator comprising: a pneumatic cylinder defining a cavity; and a piston rod disposed at least partially within the cavity of the pneumatic cylinder, wherein a first end of the piston rod and the cavity of the pneumatic cylinder define a volume of the pneumatic cylinder, and the volume of the pneumatic cylinder is configured to be pressurized to support a weight of a payload; and a positioning actuator assembly comprising: a positioning actuator comprising: a stator; and a rotor configured to rotate relative to the stator; and a connecting rod coupled to the rotor, wherein the rotor is configured to rotate to translate the connecting rod and position the payload supported by the weight bearing actuator.
 2. The motion simulation system of claim 1, further comprising a second positioning actuator assembly, wherein the second positioning actuator assembly is configured to position the payload supported by the weight bearing actuator in cooperation with the positioning actuator assembly.
 3. The motion simulation system of claim 1, further comprising a plurality of additional weight bearing actuators and a plurality of additional positioning actuator assemblies, wherein the plurality of additional weight bearing actuators are configured to be pressurized to support the weight of the payload in cooperation with the weight bearing actuator, and the plurality of additional positioning actuator assemblies are configured to position the payload supported by the weight bearing actuator and the plurality of weight bearing actuators in cooperation with the positioning actuator assembly.
 4. The motion simulation system of claim 3, wherein the plurality of additional weight bearing actuators comprises two additional weight bearing actuators and the plurality of additional positioning actuator assemblies comprises five additional positioning actuator assemblies.
 5. The motion simulation system of claim 1, further comprising a platform, wherein the platform is coupled to a second end of the piston rod and the connecting rod, and the platform is configured to support the payload.
 6. The motion simulation system of claim 1, wherein the weight bearing actuator comprises a buffer tank defining a dead volume in fluid communication with the volume of the pneumatic cylinder.
 7. The motion simulation system of claim 6, wherein a range of motion of the first end of the piston rod relative to the cavity of the pneumatic cylinder defines a swept volume, and the dead volume is between approximately 100% to approximately 500% of the swept volume.
 8. The motion simulation system of claim 1, wherein the volume of pneumatic cylinder is pressurized by oscillating the first end of the piston rod relative to the pneumatic cylinder.
 9. The motion simulation system of claim 1, wherein the positioning actuator assembly comprises a crank pivotably coupled to the rotor and the connecting rod.
 10. The motion simulation system of claim 9, wherein the crank is integrally formed with the rotor.
 11. The motion simulation system of claim 1, further comprising a linear actuator housing, wherein the weight bearing actuator and the positioning actuator assembly are at least partially disposed within the linear actuator housing.
 12. The motion simulation system of claim 11, wherein an end of the connecting rod is pivotably coupled to the piston rod between the first end and a second end of the piston rod.
 13. The motion simulation system of claim 1, further comprising a controller configured to control operation of the weight bearing actuator and the positioning actuator.
 14. The motion simulation system of claim 13, wherein the controller is configured to pressurize the volume of the pneumatic cylinder to a pressure to minimize a current draw of the positioning actuator.
 15. The motion simulation system of claim 13, wherein the controller is configured to control operation of the positioning actuator at a frequency of up to approximately 1000 Hz.
 16. The motion simulation system of claim 1, further comprising an electrical storage device configured to receive energy generated by the positioning actuator.
 17. A motion simulation system, comprising: a base; a platform movable relative to the base and configured to support a payload; a plurality of weight bearing actuators, wherein each weight bearing actuator comprises: a pneumatic cylinder pivotably coupled to the base, wherein the pneumatic cylinder defines a cavity; and a piston rod defining a first end and a second end, wherein the first end is disposed at least partially within the cavity of the pneumatic cylinder to define a volume of the pneumatic cylinder, the second end is pivotably coupled to the platform, and the volume of pneumatic cylinder is configured to be pressurized to support the platform; and a plurality of positioning actuator assemblies, wherein each positioning actuator assembly comprises: a positioning actuator coupled to the base, the positioning actuator comprising: a stator; and a rotor configured to rotate relative to the stator; and a connecting rod comprising a first end pivotably coupled to the rotor and a second end pivotably coupled to the platform, wherein the rotor is configured to rotate to translate the connecting rod and position the payload supported by the plurality of weight bearing actuators.
 18. The motion simulation system of claim 17, wherein a quantity of positioning actuator assemblies of the plurality of positioning actuator assemblies is twice a quantity of weight bearing actuators of the plurality of weight bearing actuators.
 19. The motion simulation system of claim 18, wherein the plurality of weight bearing actuators comprises three weight bearing actuators and the plurality of positioning actuator assemblies comprises six positioning actuator assemblies.
 20. The motion simulation system of claim 18, wherein the second end of the piston rod of a first weight bearing actuator of the plurality of weight bearing actuators is disposed adjacent to the second end of the connecting rod of a first positioning assembly and the second end of the connecting rod of a second positioning assembly of the plurality of positioning assemblies.
 21. The motion simulation system of claim 17, wherein the platform is movable in six degrees of freedom relative to the base.
 22. The motion simulation system of claim 17, wherein the platform comprises a plurality of legs, wherein the second end of the piston rod of each weight bearing actuator of the plurality of weight bearing actuators is coupled to a respective leg of the plurality of legs of the platform.
 23. The motion simulation system of claim 22, wherein each weight bearing actuator of the plurality of weight bearing actuator comprises a buffer tank defining a dead volume in fluid communication with the volume of the pneumatic cylinder.
 24. The motion simulation system of claim 23, wherein a range of motion of the first end of the piston rod relative to the cavity of the pneumatic cylinder defines a swept volume, and the dead volume is between approximately 100% to approximately 500% of the swept volume.
 25. The motion simulation system of claim 17, wherein the volume of pneumatic cylinder of each weight bearing actuator of the plurality of weight bearing actuators is pressurized by oscillating the first end of the piston rod relative to the pneumatic cylinder.
 26. The motion simulation system of claim 17, wherein each positioning actuator assembly of the plurality of positioning actuator assemblies comprises a crank pivotably coupled to the rotor and the connecting rod.
 27. The motion simulation system of claim 26, wherein the crank is integrally formed with the rotor.
 28. The motion simulation system of claim 17, further comprising a plurality of linear actuator housings, wherein a respective weight bearing actuator of the plurality of weight bearing actuators and a respective positioning actuator assembly of the plurality of weight bearing actuators are at least partially disposed within a common linear actuator housing of the plurality of linear actuator housings.
 29. The motion simulation system of claim 28, wherein an end of the connecting rod of the respective positioning actuator assembly is pivotably coupled to the piston rod of the respective weight bearing actuator between the first end and a second end of the piston rod.
 30. The motion simulation system of claim 17, further comprising a controller configured to control operation of the plurality of weight bearing actuators and the plurality of positioning actuator assemblies.
 31. The motion simulation system of claim 30, wherein the controller is configured to pressurize the volume of each respective pneumatic cylinder of the plurality of weight bearing actuators to a pressure to minimize a current draw of each respective positioning actuator of the plurality of positioning actuator assemblies.
 32. The motion simulation system of claim 30, wherein the controller is configured to control operation of each respective positioning actuator of the plurality of positioning actuator assemblies at a frequency of up to approximately 1000 Hz.
 33. The motion simulation system of claim 17, further comprising an electrical storage device configured to receive energy generated by the positioning actuator.
 34. A method to operate a motion simulation system, the method comprising: pressurizing a plurality of weight bearing actuators to support a platform relative to a base; and moving the platform by actuating a plurality of positioning actuators of a respective plurality of positioning actuator assemblies, wherein each positioning actuator assembly is pivotably coupled to the platform via a respective connecting rod of the plurality of positioning actuator assemblies.
 35. The method of claim 34, further comprising: detecting a current draw of each of the plurality of positioning actuator assemblies; and pressurizing the plurality of weight bearing actuators to a desired pressure to minimize the current draw of each of the plurality of positioning actuator assemblies.
 36. The method of claim 34, further comprising: supporting the platform via the plurality of positioning actuators prior to pressurizing the plurality of weight bearing actuators.
 37. The method of claim 34, further comprising: oscillating the plurality of weight bearing actuators to pressurize each respective weight bearing actuator.
 38. The method of claim 34, further comprising: successively moving the platform in response to a succession of pose vectors at a streaming frequency up to approximately 1000 Hz.
 39. The method of claim 34, further comprising: determining a respective rotational position of each of the plurality of positioning actuator assemblies; and adjusting a gain factor for each respective positioning actuator assembly in response to comparing the respective rotational position of each of the plurality of positioning actuator assemblies with a desired rotational position of each of the plurality of positioning actuator assemblies.
 40. The method of claim 34, further comprising: generating electrical energy from motion of the plurality of positioning actuator assemblies; storing the electrical energy from the plurality of positioning actuator assemblies in an electrical storage device; and deploying the electrical energy from the electrical storage device.
 41. A non-transitory computer readable medium storing instructions that are configured to cause a processor of a device to at least: detect a current draw of each of a plurality of positioning actuator assemblies; and pressurize a plurality of weight bearing actuators to a desired pressure to minimize the current draw of each of the plurality of positioning actuator assemblies.
 42. The instructions of claim 41, further configured to cause a processor of a device to at least: successively actuate the plurality of positioning actuator assemblies in response to a succession of pose vectors at a streaming frequency up to approximately 1000 Hz.
 43. The instructions of claim 41, further configured to cause a processor of a device to at least: determine a respective rotational position of each of the plurality of positioning actuator assemblies; compare the respective rotational position of each of the plurality of positioning actuator assemblies with a desired rotational position of each of the plurality of positioning actuator assemblies; and adjust a gain factor for each respective positioning actuator assembly in response to comparing the respective rotational position of each of the plurality of positioning actuator assemblies with a desired rotational position of each of the plurality of positioning actuator assemblies. 